Method of making a siding strip



y 1939- a. A.'FA'$OLU 2,164,508

METHOD OF MAKING A sIDI NcT STRIP Filed Aug. 24,1933

IN VEN TOR.

A TTORNEYS.

Patented July 4, 1939 I I UNITED STATES PATENT OFFICE METHOD OF MAKING A SIDING STRIP George Arthur Fasold, Cincinnati, Ohio, assignor to The Philip Carey Manufacturing Company, a corporation of Ohio Application August 24, 1933. Serial No. 686,491 3 Claims. (Cl. 154-2) This invention relates to building materials and signed to represent mortar has greater elevation to method of making the same. It relates more on the siding strip with respect to the web base especially to the kind of building material known than the portion thereof designed to represent as siding strip, for example slate-surfaced brick. Thus an optical effect is produced that is asphalt felt siding strip. just the opposite of what is desired. '5.

At the present time there is considerablepopu- Heretofore siding strip has also been manular demand for building material such as siding factured by distributing a colored granular mastrip. Siding strip is a preformed sheet building terial (e. g., designed to represent mortar) unicovering adapted to be secured in placeon a wall form'ly over a' strip of saturated felt coated with m in overlapping units so as to give the appearance bituminous coating material. Thereafter asof a brick wall, for example. To this end, along phaltic material has been coated as with a roller one margin of the units there is a. coating of an o g a margin of the strip v y g the layer adherent colored material such ascolored slate f ranular material fi st ppl Th r t r a granules of substantially uniform width. This ra u ar mater al of a 0 d e imitate ll marginal strip of colored material contains at brick hasbeen applied to thestrip so as to adintervals cut out parts dividing the-marginal here to the marg a p a coatinggranular colored material into lengths corre- In the caserof the type of siding last described spending to the usual length of building, bricks, as havi e n ad heretofore. t a been found for example, the width of the cut out portions impossible to obtain a satisfactorily even and corresponding to the usual distance by which Straight line of division between the. coatings of 20 bricks are spaced by mortar placed between them. t a t Colors due to t tendency of e p The remainder of the siding strip is of a color Dh tiO aterial o w unevenlyin being l contrasting to that of the marginal coating and. p to the r in f granular material; ma be black, for example,in simulation of the An th r and ev n more seri us d fli ulty has 7 color of certain types of mortar. By securing ab en that the We ght Of the two layers of mate- 25 plurality of succeeding siding strips to a wall in rial overlyin e t base-has been so excessive overlapping relation so that the marginal colored that the marginal layer ofasp al a u e coatings are spaced slightly from each other, the On t Strip e Slide ve ye Summer contrasting colors simulating brick faces and temp r e O p e q' layers O o mortar cause the completed wallto resemble a phaltic'm'aterialicoated with. granular material plurality of separate building bricks se't'in' mortar. v l i g t e e base have fiequefifly e found' Heretofore, siding strip has been made acco'rdto exhibit': as'much'as /2 inch to 1 inch. of slide i g to one method by firstimpre nati a; w bwith resultant unsightliness of; the wall-covered. material such as felt with a bituminous saturant wi l i strip and i pai e to i asr Co t n the impregnated web withfa bitumi weatherprcofing properties.

nous coating material to afford an adherent base ti a p p o thiSiIWeHtiOHTO afiorda sidfor granular surfacing material. The" web of n 's p wherein the im ul l i e rnaterial thus' prepared has been coated uni-'- countered are overcome. In'the practice ofvthis formly with a granular material of a color" (e. g., invntiofl itis'liossible' t0 e 'e's d t p Where;

red) thatis desired-for the part of the strip din theline of demarcation between the portions signed to simulate brick. Thereafter a coating O e e e'c loris.evenl and*straight; w of asphaltic material'has' been coated'over the: eportio'ns'sirnulating K f l .h granular material-to afford a contrasting black r a lev ion than the" por o Simulating color. The last coating ofasplialtic material has 'morta-rland whereinfno part of he ip i 5 then been duste'dwithsulfi cient mica flakes, for such-excessive weight as to cause undue s ding: example, to prevent the siding" strip. units from. It is a; feature offoneembodiment Lot thisin 1 sticking together in shipment. V vention thatweb materialsuch as felt bitumi- A difiiculty arisingiintconnection.withthe type ni z'd' with; bituminous saturating and coating of siding strip just described-has been thatth'e'f material'hasadherently applied'thereto one or 0 coating of' asphaltic m'ate'ria'll overlying; the more'ribbons or strips ofsheet'material such as 0; granular material does not layievenlwariddoe's" cater totheweb; The exposed (upper) surface not produce an evenfand;straight'line' of division of} theshe'et material'is preferably substantially between the portions ofithe strip contrasting' in non-adhesive in, that granular or: fpulverulent' color. Afurther disadvantagehas resultedfrom material hasflittle tendency to'adhereth ereto, H

the fact that the portion- 0f the siding strip; (re-- The: bituminized surface of "the'web base: which is" 5 1 not covered with the non-adhesive sheet material has applied adherently thereto a granular material of desired color.

The ribbons of paper or other sheet material that is used in manufacturing sheet building covering embodying this invention is preferably relatively thin so that the paper is substantially "less thick than the coating of slate granules which is also adherent portions of the web base, Thus the granuleshave greater elevation with respect to the web base than the portions of strip covbodying this invention are secured in place in normal overlapping relation on a wall.

adherent directly to one portion of the outer sur- It is apparent that in practicing this invention it is necessary to employ but one layer of coating material coated with granules while still producing desired efiects of contrasting color. Thus, siding strip manufactured according to this invention is free from an uneven line of demarcation between portions of contrasting color and can be made so that the weight of material overlying the web base is so slight that the tendency of the strip to slide is reduced to a minimum.

It is important in the practice of this invention that the foregoing features are achieved while at the same time affording a siding strip in which the tendency to slide of the surface forming parts is substantially completely eliminated.

In the co-pending application of Harold W. Greider and myself, filed July 20, 1933, Serial No. 681,286, which has now matured into Patent No. 2,105,531, dated January 18, 1938, for Bituminized web materials and method of and apparatus for making the same, there is disclosed a method of impregnating felt so that it is filled with two types of bituminous material, the core or inner part of the felt being impregnated with a relatively soft bituminous saturant and a surface layer of substantial depth of the felt being impregnated with a bituminous coating material of substantially higher softening point than the softening point of the saturant. According to this invention, a felt so prepared is caused to have face of the bituminous coating fnaterial a sheet or layer of one character and appearance and to have adherent directly to'another portion of the said outer surface of the bituminous coating material a granular material which is of different character and appearance from said sheet or layer and which is adapted for the ornamental marginal portion of the siding strip. In this way, the coating material is keyed into the felt foundation of the siding strip and the softer saturant at the core of the felt is prevented from bleeding to the surface of the felt so as to form what is in effect a lubricant over the felt; and since both the ornamental marginal material and the contrasting material, e. g., sheet material, are directly adherent the coating material which is keyed to the felt, a siding strip is afforded which has the combined properties of improved omamental quality and of being non-sliding in all parts thereof.

For they purpose of affording an illustration of the practice of this invention one method of makthis invention will be described in connection with the accompanying drawing, wherein Figure 1 is a schematic representation of one form of apparatus whereby siding strip may be manufactured according to this invention;

Fig. 2 is aplan view of a sheet of web material coated alternately with ribbons of sheet material and with coatings of granular material prior to the cutting of the same into siding strips;

Fig. 3 is a perspective view of a portion of siding strip embodying a preferred form of this invention with a part thereof magnified;

Fig. 4 is a sectional view of the siding strip taken on the line 4-4 of Fig. 3 with a part thereof magnified; and

Fig. 5 is'a perspective view of a wall covered with siding strip embodying-this invention and illustrating one form of ornamental design produced thereby.

Referring to the drawing, a sheet of felt or other web material In is taken from any suitable source not shown over roller ii to saturating tank l2 where it passes alternately over rollers 13 below the surface of the saturant [4 in tank I2 and rollers 15 above the surface of the saturant. After passing from saturating tank i2 and prior to passing over roller IS the web of material is passed between doctor blades ll which remove excess saturant from the web. The saturated web is then coated with coating material 18 in coating tank l9 as described in the aforesaid Patent No. 2,105,531 by passing the same from guide roller to squeeze rollers 215 which are between guide rollers 2| and 22 and which compress the web l0 therebetween while it is submerged beneath the surface of coating material l8 so as to devoid the web by compression'and permit the web to expand while submerged in the coating material so as to become coated and sealed in a devoided condition. Excess coating material is removed from the web by doctor blades 23 between guide roller 22 and guide roller 24 above the surface of coating material in tank i9. Coating material 45 is .applied to the web from pipe 26 and is spread to desired thickness by spreading rollers 21.

By the method and apparatus above described the web material is thoroughly filled with saturant and is sealed in a devoided condition with coating material as described in application-Serial No. 681,286, above mentioned. The bituminous coating material penetrates the felt to substantial depth as a continuous and uniform layer against the web It by means of one or more roll-'- ers 30. The roller or rollers 30 which are on the same side of the web l0. as thepaper 29'preferably correspond in width to the width of the ribbon or ribbons 29 so that the same will not com'e into' contact with the part of the web ID that has-not been covered with paper.

The web ill is passed under a hopper 3| adapted to apply a granular'materiai 38, for example, of

desired color to the bituminized web I0. As the of the ribbon 29 of sheet material should be such that the granular material will not substantially adhere thereto. The inner surface of the ribbon 29 adheres to the web 10 by a suitable adhesive and may or. may not be adhesive prior to application to the web Ill. The Web ID is now passed over rolls 28, 32 and 33. In passing between rolls 28 and 32 the, web receives on the back thereof an application of a finely divided material 39 such as mica flakes, for example, from hopper 34. Any

other suitable separating material may also be employed. While it is not essential to the prac tice of this invention the web of material may be passed between rollers 35 to press the granular and finely divided material into the bituminous coating material on web l and cause the same nal lines 40 to produce strips having granular surfacing material along and adjacent one margin thereof and sheet material forming the surface along and adjacent the other margin thereof. The web base may also be out along lateral lines 4| so as to produce strips of any desired length. Moreover, the laterally extending holes or cut-out portions 42 may be punched out as indicated by the lines 42 in Fig. 2. The cut-out parts 42 are preferably punched at more frequent intervals than the cuts 4| so that each siding strip may include a plurality of portions representing bricks, for example, spaced from each other by the cut-out portions 42.

Any suitable cutting and punching mechanisms may be employed. In Fig. 1 means for cutting this web lil'longitudinally is indicated generally by the reference character 43. Means for cutting the web Ill-laterally and punching openings therein is indicated diagrammatically by the reference character 44.-

A specimen of a siding strip embodying this invention is shown in Figs. 3 and 4. The strip comprises a web l0 impregnated with a.bituminous saturant l4. The web is impregnated adjacent the surfacethereoi' with bituminous coating m'aterial I8. Thus the web comprises a layer offelt impregnated with saturant andanother layer of felt impregnated with coating materiaL'the felts ,web I4. The paper or other sheet material 29 adheres to coating 45. The granular material 38 also adheres to the coating 45 at points .notcovered by paper 29. Thus the web'base has granular material adherent thereto by virtue of bituminous adhesive material directly interposed .between the web base-and-granular material. Also theweb base has sheetmaterial adherent :thereto 1 byvirtue ,of the said bituminous adhesive material also e t r c e w e the. sheet material "a th web .1 1211 strip .q gnn r mortars of v different colors. rial is preferably employed according -to this individed material 39, such as mica flakes to prevent the strips from sticking during shipment.

The appearance of the siding strip when manufactured to simulate brick, for example, and seowed to the wall 41 of a building is shown in Fig. 5. The granular material 38 gives the appearance of the faces of bricks. The sheet material 29 shows between spaced portions coated with granular material 38 and gives the appearance of mortar between faces of bricks. The strips may be of any desired length and contain any number of separated lengths of granular surfacing material 38. Moreover, the web may be cut into separate shingles. The ends 46 of the strips may be cause to abut each other as shown. The, strips may be affixed to the wall 41 as by nails 48.

The siding strip embodying this invention is seen to have the following advantages. The line between the paper or other sheet material 29 and granular material 38 is very sharp giving a neat appearance to a wall covered with the siding strip. The granular material 38 is more prominent with respect to the felt base than the paper 29 thus giving a desiredeffect that makes a wall covered with the siding strip have a highly realistic appearance. At the same timeno part of the strip has more than one layer of material overlying the coating material and the coating material impregnates the web base of the strip to substantial depth so as to be keyed thereto. Thus the tendency of the materials overlying the web base to slide with respect to the web base is reduced to a minimum if not eliminated altogether. This tendency to slide has been a very serious defect in siding strip heretofore made. As the siding strip has only a small part thereof covered with granular material, great economy is effected with respect to the amount of granular material that is used. Moreover, the necessity for coating granular material with overlying layers of bituminous coating material is eliminated with resulting economy of bituminous materials that are used and of manipulations necessary in manufacturing the siding strip.

While mention has been made of the employment of paper in the manufacture of siding strip embodying this invention, it is to be understood that this has been done merely for the purpose of illustration,as any paper, felt, fabric or sheet of material may be employed according to this invention. It ispreferable to employ sheet material which is impregnated rvith a material that renders the paper weather-resistant. Such paper is referred to herein as weatherproofed. Thusa paper that is saturated and/or coated with a relatively non-adhesive bituminous material is desirable .for use in practicing this invention. The paper may or may'not be coated with mineral surfacing material. Moreoverpthe color of the sheet material that is used can be varied as desired to produce different effects such, for example, as the effects resulting from the use of While sheet matevention it --is not without the .scopethereof to employ; other materials adhering to a\ web of materialcoatediwith adhesive material. For examplegaluminum foil orother thin sheet metal could b'e instead of paper for the production iofgcertaineflects. I

.rtiis-galso td be regarded ascoming within the scope of this invention to afford a preformed ornamental-sheet building.covering such as sidlirg- Strip web base, a first colored said web base-by virtue of employment of granular and non-granular materials of contrasting color thus directly adherent to a web base and forming difi'erent'portions of the surface that is normally exposed to view when a plurality of the preformed units are secured in place to form parts of an ornamental design is also to be regarded as coming within the scope of this invention.

-While mention has been made of the use of felt as a web material other web materials may also be used such as wovenmaterials. Moreover, while the use of bituminous saturants and bituminous adhesive coatings for web materials has been mentioned as preferable, other adhesive coatings for a web may be used such as rubber latex, shellac, varnishes and the like. The term granular material should also be construed as including any granular or finely-divided solid material adapted to adhere to an adhesive material and form a coating for sheet building covering of the haracter described.

In the manufacture of siding strip using bituminous saturating and coating materials, it is usually preferable to employ usual types of shingle saturant and coating materials. For example, saturant having a softening point of 95 F. to 140 F. (as determined by the ball and ring method (and having a .penetration of about 10 to 30 at 77 F. as determined by a Dpw penetrometer, may be employed. Considerable latitude is permissible, however, as satisfactory results also result when the saturant has a softening point of about 75 F. to about.200 F. and a penetration of about 5 to about 200 at 77 F. Thesaturant is preferably applied at a temperature of about 350 F. to about 400 F.

The bituminous coating material preferably has a softening point between about 200 F. and

about 250 F. and has a penetration of about 9 to about 20 at 77 F. However, satisfactory results are also obtained .when the softening point ranges fromabout 190 F. to about 275 F. and

the penetration ranges from about 50 to 5 at 77 F. The coating material is preferably applied at about 425 F., although about 50 F. to about F. variation from this figure will still afford satisfactory results,

In manufacturing the bitumlnized. web and coating the same with a granular material the portion of the siding strip which is surfaced with the granular material should preferably be-made so that the weight of the bituminous coating material and solid granular material overlying the web material is less than about 45 pounds per 100 sq. ft. so as to minimize the tendency thereof.

of the overlying material to slide. However, if the weight ofbituminous coating material is less than 15 lbs. per 100 sq. ft. and large, heavy granules are applied, it is practicable to increase the total weight of material'overlying the web somewhat without inducing a tendency to slide.

While this invention has been described in connection with certain specific illustrations thereof it is to be understood that this has been done for the purpose of illustration merely and this invention is to be limited only by the scope of the following claims.

I claim:

1. A method of making siding strip which comprises saturating a web material with a bituminous saturant, immersing the web of material in a bath of bituminous coating material having a higher softening point than said saturant, compressing the web to devoid same and permitting it to expand while submerged in said bituminous coating material thereby impregnating said web with a continuous uniform layer of substantial depth in said felt of said coating material, removing excess coating material from the surface of said web,applying adherentlytosaidcoatingmaterial while it is adhesive apaper having a substantially non-adhesive outer surface, applying adherently to said coating material which is not covered by said paper while it is adhesive a granular material, and cutting said web into strips having granular material along and adjacent the surface of the margin thereof and having paper along and adjacent the surface of the other margin thereof.

said bituminous coating material as aforesaid so.

as. to become impregnated with a continuous layer of substantial depth in said felt of said coating material, removing excess coating material from the surface of said web, applying granular material in spaced bands so as to adherently overlie said coating material, applying colored surfacing material the color of which contrasts with the color of said granular material so as to adherently overlie said coating material between said bands of granular material, and cutting said web into strips having said granular material along and adjacent the surface ofa marginal portion thereof andhaving said material of contrasting color forming the surface of another portion J 3. The process of claim 2 wherein the said squeezing of said web is progressive and said web is released from the squeezing while submerged in said'bituminous coating material.

GEORGE THUR r'AsoLD. 

